Futon mattress

ABSTRACT

A futon mattress ( 10 ) having a cover ( 14 ) with a plurality of pockets for retaining filler material ( 18 ). The cover ( 14 ) having a top surface ( 22 ) coupled to a bottom surface ( 26 ). A closure device ( 34 ) is coupled to the cover ( 14 ) to selectively allow access to the inside surfaces of the cover ( 14 ). In some embodiments, the closure device also allows the top ( 24 ) and bottom ( 26 ) surfaces to be selectively uncoupled from each other. The top surface ( 22 ) of the cover ( 14 ) has a first plurality of pockets ( 38 ) that are accessible only from inside the cover ( 14 ). A filler material ( 18 ), such as viscoelastic foam for example, is contained within each pocket ( 38, 42 ) of the first plurality of pockets. Some embodiments also include a second plurality of pockets ( 42 ) positioned along an inside surface of the bottom ( 26 ) of the cover ( 14 ). The second plurality of pockets ( 42 ) can also contain a filler material ( 18 ) that accessible only from inside the cover ( 14 ).

BACKGROUND OF THE INVENTION

Futon mattresses generally have cushioning filler material encased in aprotective cover. For example, some futon mattresses are filled withcotton batting, wool batting, foam, or the like to provide sufficientcushioning. However, due to the many uses for a futon cushion, the outercover can become easily soiled. The cover of most conventional futoncushions can not be easily cleaned because the cover cannot beconveniently separated from the cushioning filler material.

SUMMARY OF THE INVENTION

The present invention generally relates to a futon mattress havingmultiple pockets for storing filler material within the cover of themattress. The filler material can be removed from the pockets and thecover to allow the cover to be easily laundered. In some embodiments,the top of the cover can be separated from the bottom of the cover toallow the top to be separately laundered.

One embodiment of the invention relates to a futon mattress including acover having a top portion coupled to a bottom portion and a closuredevice coupled to the cover to selectively allow access to insidesurfaces of the top and bottom portions of the cover. A first pluralityof pockets are positioned along an inside surface of the top portion ofthe cover and contain a filler material accessible only from inside thecover. A second plurality of pockets are positioned along an insidesurface of the bottom portion of the cover and contain a filler materialaccessible only from inside the cover.

Another embodiment relates to a futon mattress having a cover with a topportion selectively coupled to a bottom portion via a closure devicepositioned between the top portion and the bottom portion. The closuredevice is movable to selectively allow the top portion to uncouple fromthe bottom portion. The top portion of the cover has a first layer ofpockets, while the bottom portion of the cover has a second layer ofpockets. The first layer of pockets and the second layer of pockets arefilled with a filler material.

Another embodiment relates to a futon mattress having a cover with a topsurface coupled to a bottom surface, where the top and bottom surface ofthe cover each have a length and a width. A zipper is positioned alongthe interface between the top surface and the bottom surface toselectively allow the top surface to uncouple from the bottom surface. Afirst plurality of pockets are positioned along an inside surface of thetop of the cover and contain a first filler material accessible onlyfrom inside the cover. The first plurality of pockets are positionedside-by-side along the length of the top of the cover. A secondplurality of pockets are positioned along an inside surface of thebottom of the cover and contain a second filler material accessible onlyfrom inside the cover. The second plurality of pockets are positionedside-by-side along the length of the bottom of the cover.

These and other aspects of the present invention, together with theorganization and operation thereof, will become apparent from thefollowing detailed description of the invention when taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein like reference numerals indicate like parts:

FIG. 1 is a perspective view of a futon mattress embodying aspects ofthe present invention, wherein the futon mattress is folded into astorage position.

FIG. 2 is a perspective view of the mattress illustrated in FIG. 1,wherein the futon mattress is unfolded.

FIG. 3 is a perspective view of the mattress illustrated in FIG. 2,where the top portion of the mattress is separated from a bottom portionof the mattress.

FIG. 4 is a perspective view of the bottom of the mattress illustratedin FIG. 3 with the filler material of the bottom portion of the mattressbeing partially removed.

FIG. 5 is a perspective view of the top of the mattress illustrated inFIG. 3 with the filler material of the top portion of the mattress beingpartially removed.

FIG. 6 is a cross-sectional view of a portion of the mattress shown inFIG. 2.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limited. The use of“including,” “comprising” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. The terms “mounted,” “connected” and“coupled” are used broadly and encompass both direct and indirectmounting, connecting and coupling. Further, “connected” and “coupled”are not restricted to physical or mechanical connections or couplings,and can include electrical connections or couplings, whether direct orindirect.

DETAILED DESCRIPTION

FIGS. 1-6 illustrate one embodiment of the present invention. As shownin FIGS. 1 and 2, the illustrated mattress is adapted for use as a futonmattress. In other words, the mattress can be easily folded or otherwisemanipulated to change the configuration of the mattress from a fullylaid-out position, as illustrated in FIG. 2, to a folded position, asillustrated in FIG. 1. Manipulation of the mattress, as shown in FIG. 1,can allow it to be easily stored or used for other purposes such asseating.

As best illustrated in FIGS. 2 and 6, the illustrated mattress 10 has afabric case or cover 14 filled with filler material 18. The cover 14contains and protects the filler material 18. The cover 14 has a topportion 22 coupled to a bottom portion 26 along a perimeter 30. The topportion 22 can be coupled to the bottom portion via stitching, adhesiveor cohesive bonds, and the like. Furthermore, a closure device 34, suchas a zipper, hook and loop fastener, and the like can be coupled to themattress to allow selective access to the interior portions of themattress 10. The closure device 34 can form part of the coupling betweenthe top portion 22 and the bottom portion 26 of the cover 14. The accessallowed by such closure devices 34 can be used to reconfigure or removefiller material 18 from the cover 14. With the filler material removed,the cover 14 can be easily laundered.

Since the top portion 22 of the mattress 10 is more likely to be soiled,it may be desirable in some situations to only launder the top portion22 of the cover 14 without laundering the bottom portion 26.Accordingly, in some embodiments, the closure device 34 can form theentire coupling between the top portion 22 and bottom portion 26 of thecover 14. In such embodiments, the top portion 22 can be separated oruncoupled from the bottom portion 26 to be separately laundered, ifdesired. For example, as illustrated in FIGS. 2 and 3, the closuredevice 34 or zipper can be actuated to separate or uncouple the topportion 22 of the cover 14 from the bottom portion 26 of the cover 14.

Although the illustrated embodiment shows that the top portion 22 can beseparated or uncoupled from the bottom portion 26 to remove the topportion 22 from the bottom portion 26, other embodiments can allow theseportions to be separated, but not removed from each other. For example,in some embodiments, the top portion 22 can be coupled to the bottomportion 26 along a substantial portion of perimeter 30 via a closuredevice 34, while a seam or other substantially permanent connection isused to connect the top portion 22 to the bottom portion along only aportion of the perimeter 30. In some embodiments, the top portion 22 canbe substantially permanently connected to the bottom portion 26 along atleast one side or edge of the cover 14. Accordingly, in thesealternative embodiments, the top portion 22 can be separated from thebottom portion 26 such that it can be positioned on a support surfaceadjacent the bottom portion 26 to allow access to interior portions ofthe cover 14.

The cover 14 can be made from many different materials. In someembodiments, the top portion 22 of the cover 14 is formed from a firstmaterial, while the bottom portion 26 of the cover 14 is formed from asecond material. For example, the top portion 22 of the cover 14 canhave a relatively soft velour feel, while the bottom portion 26 of thecover 14 can be made from a non-slip material. However, in otherembodiments, both the top portion 22 and the bottom portion 26 of thecover 14 are made from the same type of material.

As illustrated in FIGS. 3-6, the cover 14 includes multiple pockets 38,42 for holding the filler material 18. A first plurality of pockets 38are connected to the top portion 22 of the cover 14. The first pluralityof pockets 38 are arranged in a layer or positioned side-by-side alongthe top portion 22 of the cover 14 to substantially cover the entirelength L of the cover 14. Each pocket within the first plurality ofpockets 38 extends substantially across the width W of the cover 14. Inother constructions, however, two or more pockets can extend across thewidth W of the cover 14. For example, it may be desirable in someembodiments to provide different levels of cushioning on each side ofthe mattress corresponding to a specific user's desire.

Each illustrated pocket within the first plurality of pockets 38 isshown as fully enclosing filler material 18 within the pocket. Eachillustrated pocket within the first plurality of pockets 38 also has aclosure device 46 to fully contain the filler material 18 within thepocket, prevent the filler material 18 from unintentionally escaping thepocket, and allow selective access within the pocket. As illustrated,the pocket closure device 46 can be a zipper, but in other embodiments,it can include hook and loop fasteners and the like. The illustratedpocket closure device 46 is positioned on a surface of each pocket thatis only accessible from inside the cover. In other words, the coverclosure device 34 must be opened prior to being able to access andmanipulate the pocket closure device 46. As illustrated in FIGS. 3 and5, the pocket closure device 46 can be located on a surface 50 of eachpocket that is substantially parallel to the top surface 22 of the cover14. With this construction, the pocket closure device 46 is positionedbeneath the filler material 18 when the mattress 10 is used in theunfolded position. Accordingly, the chance that the pocket closuredevice 46 will be felt by a person resting on the mattress is reduced.Although the illustrated embodiment shows the pocket closure device 46extending across the bottom surface 50 (as shown in FIG. 6) of thepocket, in other embodiments, the closure device can be positionedaround at least a portion of the perimeter of each pocket.

Although the illustrated embodiment has a pocket closure device 46 oneach pocket of the first plurality of pockets 38, in other embodiments,a closure device 46 is not used. For example, each pocket can beconstructed to fully enclose the filler material 18 without sealing theopening 54 of the pocket. Specifically, the opening 54 of the pocket canhave overlapping pieces of fabric that prevent the filler material 18from unintentionally escaping the pocket. Furthermore, assuming thateach pocket is properly sized for the filler material 18, the pocketwould not have to fully enclose the filler material 18. Rather, it couldmerely enclose the perimeter of the filler material 18.

As illustrated in FIGS. 3, 4, and 6, the futon mattress also has asecond plurality of pockets 42 that are connected to the bottom portion26 of the cover 14. The second plurality of pockets 42 are arranged in alayer or positioned side-by-side along the bottom portion 26 of thecover 14 to substantially cover the entire length L of the bottomportion 26 of the cover 14. Each pocket within the second plurality ofpockets 42 extends substantially across the width W of the cover 14.However, in other constructions, two or more pockets can extend acrossthe width W of the cover 14. For example, it may be desirable in someembodiments to provide different levels of cushioning on each side ofthe mattress corresponding to a specific user's desire.

Unlike the first plurality of pockets 38 which are shown as being fullyenclosed, the illustrated second plurality of pockets 42 do not fullyenclose the filler material 18 within each pocket. Rather, each pocketwithin the second plurality of pockets 42 merely enclose the perimeterof the filler material 18 to prevent movement of the filler material 18within the mattress 10. However, other embodiments can fully enclose thefiller material 18 if desired. For example, it may be desirable to fullyenclose the filler material 18 when a loose filler material 18, such asgranular or shredded foam, foam beads, loose cotton, and the like isused within the second plurality of pockets 42. Accordingly, someconstructions may also use a pocket closure device 46 as well to fullycontain the filler material 18 and prevent the filler material 18 fromunintentionally escaping the pocket. Like the first plurality of pockets38, the pocket closure device 46 can be positioned on a surface of eachpocket that is only accessible from inside the cover 14.

As shown in the illustrated embodiment, each of the pockets in thesecond plurality of pockets 42 has a fabric lip 58 that extends aroundone surface of the pocket to engage the perimeter of the filler material18, such as a block of foam. The fabric lips 58 extend in a directionsubstantially parallel to the top and bottom surfaces 22, 26 of thecover 14. Furthermore, an opening 54 defined by the lips 58 isaccessible only from inside the cover 14.

Although the illustrated embodiment shows each pocket within the sameplurality of pockets has having the same construction, in otherembodiments, one or more pockets within the same plurality of pocketscan have a different construction relative to the other pockets withinthe same plurality of pockets. For example, one or more pockets withinthe second plurality of pockets 42 can be fully enclosed while theremainder of the pockets utilize the lip 58 construction describedabove. Similarly, one or more pockets of the first plurality of pockets38 can utilize a non-fully enclosed structure while the remainder of thepockets are fully enclosed.

As illustrated in FIGS. 2, 3, and 6, the first and second plurality ofpockets 38, 42 can each comprise a different number of pockets. Forexample, in the illustrated embodiment, the first plurality of pockets38 includes seven pockets and the second plurality of pockets 42includes four pockets. Accordingly, as illustrated, two pockets of thefirst plurality of pockets 38 are generally provided for each pocket ofthe second plurality of pockets 42. Due to this arrangement, the end ofcertain pockets within the each of the plurality of pockets generallyalign to form a convenient fold location for the futon mattress 10.However, in some embodiments, the ends of pockets do not need to alignto form fold locations. Furthermore, the size and number of pocketswithin each plurality of pockets 38, 42 can vary. Thus, each pluralityof pockets can include more or less pockets than illustrated.

Although some pockets are illustrated as having equal lengths, thelength of each pocket does not have to be the same. Rather, the lengthcan vary depending upon the location of the pocket on the mattress 10.For example, some mattresses are divided into zones that correspond withlocations of different areas of the body. Accordingly, the pockets canhave different lengths corresponding to the desired size of severalzones on the mattress. For example, an average person's hips willgenerally fall within a predetermined area on the mattress and need tosink into the mattress more than the small of the back to properly alignthe spine. Thus, a zone having a select length and filler material 18characteristics can be positioned in this area. The adjacent zones canhave different lengths and/or filler material 18 characteristics toproperly align the back and legs with the hips.

As described above, each pocket is designed to at least partiallycontain a filler material 18, which provides a cushioning effect for themattress 10. The filler material 18 can include a wide variety ofcushioning materials. For example, the filler material 18 of themattress 10 can include cotton batting, wool batting, foam such asviscoelastic foam, polyurethane foam, highly resilient (HR) foam, orother foams commonly used in the industry, and the like. The selectionof materials can depend upon the desired feel of the mattress.Furthermore, the filler material can be formed as blocks, strips, orwebs, or it can be placed in the pockets in a loose or granular form.Additionally, a combination of different filler material types and formscan be used in a single pocket.

The filler material 18 of each pocket can be individually selected toprovide a desired feel in the mattress 10. Accordingly, one or more ofthe pockets can be filled with the same material or one or more pocketscan be filled with different materials. In the illustrated embodiment,the first plurality of pockets 38 are filled with a first type of fillermaterial 18 and the second plurality of pockets 42 are filled with asecond type of filler material 18. More specifically, the firstplurality of pockets 38 are filled with a first type of foam and thesecond plurality of pockets 42 are filled with a second type of foam.The first type of foam is a viscoelastic foam sold by Tempur World, LLCof Lexington, Ky., U.S.A. under the trademark Tempur®. The second typeof foam is a highly resilient foam. In possible alternative embodiments,each first plurality of pockets and/or each second plurality of pocketsis filled with a combination of two or more types of foam, however, onetype of foam being the primary type of foam in the pocket in question.It will also be possible filling selected first pockets with one type offoam or with more types of foam, and filling remaining first pocketswith another type of foam or with other more types of foam. The samepossibility applies to selected second pockets and remaining secondpockets.

As illustrated in FIGS. 3 and 4, foam filler material is formed asstrips or blocks. These strips are covered by a netting material 62 orother fabric and inserted into the pockets of the cover 14. The netting62 can help to protect the foam when being inserted and removed from thepockets. Additionally, depending upon the type of material used for thenetting 62, the netting 62 can control the amount of sheer force orfriction force between the pockets and the filler material. For example,it may be desirable to use a material that reduces the sheer force toallow easier movement between the filler material and the pocket. Thiscan reduce the effort needed to insert and remove the filler material 18from the pockets. However, in some embodiments, a material with agreater sheer force can be selected to reduce the amount and/or ease ofmovement of the filler material within the pocket.

As illustrated, the foam blocks are roughly the same size as thepockets. However, the foam can be made slightly larger or smaller thanthe size of the pockets. For example, in some embodiments the pocketsare designed to fit snuggly over the foam to provide a firm feel. Inother embodiments, the pockets are not as snug to provide a softer feel.

The embodiments described above and illustrated in the figures arepresented by way of example only and are not intended as a limitationupon the concepts and principles of the present invention. As such, itwill be appreciated by one having ordinary skill in the art that variouschanges in the elements and their configuration and arrangement arepossible without departing from the spirit and scope of the presentinvention. For example, some embodiments of the invention have beendescribed with reference to specific types of filler material, such ashighly resilient foam and visco-elastic foam. However, the type andshape of the filler material may be different, without departing fromthe scope of protection. Furthermore, some embodiments referenced aspecific pocket construction in specific locations on the mattress. Thespecific construction of the pocket relative to the location of thepocket can vary without departing from the scope of protection.

Variations and modifications of the foregoing embodiments are within thescope of the present invention. It is understood that the inventiondisclosed and defined herein extends to all alternative combinations oftwo or more of the individual features mentioned or evident from thetext and/or drawings. For example, various alternatives to the certainfeatures and elements of the present invention are described withreference to specific embodiments of the present invention. With theexception of features, elements, and manners of operation that aremutually exclusive of or are inconsistent with each embodiment describedabove, it should be noted that the alternative features, elements, andmanners of operation described with reference to one particularembodiment are applicable to the other embodiments. All of thesedifferent combinations constitute various alternative aspects of thepresent invention.

Various features of the invention are set forth in the following claims.

1. A futon mattress comprising: a cover having a top portion coupled toa bottom portion; a closure device positioned between the top portionand the bottom portion; a first layer of pockets positioned along thetop portion of the cover; a second layer of pockets positioned along thebottom portion of the cover; and filler material positioned within thefirst layer of pockets and the second layer of pockets.
 2. The futonmattress of claim 1, wherein the cover having a top portion isselectively coupled to the bottom portion.
 3. The futon mattress ofclaim 1 or of claim 2, wherein the closure device is coupled to thecover to selectively allow access to inside surfaces of the top andbottom portions of the cover.
 4. The futon mattress of any of claims1-3, wherein the closure device is movable to selectively allow the topportion to uncouple from the bottom portion.
 5. The futon mattress ofany of claims 1-4, wherein the first layer of pockets comprise aplurality of pockets positioned along an inside surface of the topportion of the cover and containing a filler material accessible onlyfrom inside the cover.
 6. The futon mattress of any of claims 1-5,wherein the second layer of pockets comprise a plurality of pocketspositioned along an inside surface of the bottom portion of the coverand containing a filler material accessible only from inside the cover.7. The futon mattress of any of claims 1-6, wherein the top and bottomportion of the cover each have a length and a width, and wherein thefirst layer of pockets are positioned side-by-side along the length tosubstantially cover the top portion of the cover.
 8. The futon mattressof claim 7, wherein the first layer of pockets substantially cover aninside surface of the top portion of the cover.
 9. The futon mattress ofclaim 7, wherein each pocket of the first layer of pockets extendssubstantially across the width of the cover.
 10. The futon mattress ofclaim 7, wherein the second layer of pockets are positioned side-by-sidealong the length to substantially cover the bottom portion of the cover.11. The futon mattress of claim 10, wherein the second layer of pocketssubstantially cover an inside surface of the bottom portion of thecover.
 12. The futon mattress of claim 10, wherein each pocket of thesecond layer of pockets extends substantially across the width of thecover.
 13. The futon mattress of claim 1, wherein the filler materialfor the first layer of pockets is a first filler material, said firstfiller material primarily consisting of a viscoelastic foam.
 14. Thefuton mattress of claim 13, wherein the first filler material comprisingthe viscoelastic foam filler material for each pocket is containedwithin a fabric covering.
 15. The futon mattress of claim 13, whereinthe filler material for the second layer of pockets is a second fillermateriel, said second filler material being different than the firstfiller material in the first layer of pockets.
 16. The futon mattress ofclaim 15, wherein the second filler material for each pocket of thesecond layer of pockets is contained within a fabric covering.
 17. Thefuton mattress of claim 15, wherein the second filler material for thesecond layer of pockets primarily consists of a non-viscoelastic foam.18. The futon mattress of claim 1, further comprising a zipper on eachpocket in the first layer of pockets to selectively open and close eachpocket to allow the filler material to be selectively removed, thezipper being accessible only from inside the cover.
 19. The futonmattress of claim 1, wherein the closure device is a zipper.
 20. Thefuton mattress of claim 1, wherein each pocket of the first and secondlayer of pockets is accessible only from inside the cover to remove thefiller material.
 21. A futon mattress comprising: a cover having a topportion coupled to a bottom portion; a closure device coupled to thecover to selectively allow access to inside surfaces of the top andbottom portions of the cover; a first plurality of pockets positionedalong an inside surface of the top portion of the cover and containing afiller material accessible only from inside the cover; and a secondplurality of pockets positioned along an inside surface of the bottomportion of the cover and containing a filler material accessible onlyfrom inside the cover.
 22. The futon mattress of claim 21, wherein thetop and bottom portion of the cover each have a length and a width, andwherein the first plurality of pockets are positioned side-by-side alongthe length to substantially cover the inside surface of the top portionof the cover.
 23. The futon mattress of claim 22, wherein each pocket ofthe first plurality of pockets extends substantially across the width ofthe cover.
 24. The futon mattress of claim 22, wherein the secondplurality of pockets are positioned side-by-side along the length tosubstantially cover the inside surface of the bottom portion of thecover.
 25. The futon mattress of claim 24, wherein each pocket of thesecond plurality of pockets extends substantially across the width ofthe cover.
 26. The futon mattress of claim 21, wherein the fillermaterial for each pocket is contained within a fabric covering.
 27. Thefuton mattress of claim 21, wherein the filler material contained withineach pocket of the first plurality of pockets comprises a viscoelasticfoam
 28. The futon mattress of claim 21, wherein the filler material forthe second plurality of pockets is different than the viscoelastic foamfiller material in the first layer of pockets.
 29. The futon mattress ofclaim 21, further comprising a zipper on each pocket in the firstplurality of pockets to selectively open and close each pocket to allowthe filler material to be selectively removed, the zipper beingaccessible only from inside the cover.
 30. The futon mattress of claim21, wherein the closure device is a zipper coupled to the cover.
 31. Thefuton mattress of claim 30, wherein the zipper is positioned along atleast a portion of an interface between the top portion and the bottomportion.
 32. The futon mattress of claim 21, wherein the closure deviceis positioned along an interface between the top portion and the bottomportion to selectively allow the top portion to be uncoupled from thebottom portion of the cover.
 33. A futon mattress comprising: a coverhaving a top surface coupled to a bottom surface, the top and bottomsurface of the cover each have a length and a width; a zipper positionedalong an interface between the top surface and the bottom surface of thecover to selectively allow the top surface to uncouple from the bottomsurface; a first plurality of pockets positioned along an inside surfaceof the top of the cover and containing a first filler materialaccessible only from inside the cover, the first plurality of pocketspositioned side-by-side along the length of the top of the cover; and asecond plurality of pockets positioned along an inside surface of thebottom of the cover and containing a second filler material accessibleonly from inside the cover, the second plurality of pockets positionedside-by-side along the length of the bottom of the cover.